BK3000 FLOW MONITOR - For Gas or Liquid Meters -

Transcription

1 Intrinsically Safe When Installed Per Drawing - B Sécurité intrinsèque lorsqúll est installé par le dessin B CLASSIFIED BK3000 FLOW MONITOR - For Gas or Liquid Meters - PROGRAMMING & INSTALLATION MANUAL K 1 2 Menu S1 Enter S4 K COM Up S3 XXXXXXXXXX XXXXXXXXXX Pulse Output Reset Input Turbine Input V Max 28 Vdc 5 Vdc Voc = 3.5 V I Max 100 ma 5 ma Ics = 3.6 ma Ci Li 0.0 μf 0.0 mh 0.0 μf 0.0 mh Ca = 1.5 μf La = 1.65 H WARNING: Substitution of Components May Impair Intrinsic Safety ADVERTSSEMENT: La Substitution De Composants Peut Compromettre La Seccurtie Intrinseque Class I Div 1 Groups C,D Class I Zone 0, IIB, T4 Class II Div 1 Groups E,F,G Class III Max Ambient 70 C Do not open when an explosive atmosphere may be present. WARNING - Do not open when energized. Install seal within 18 inches of enclosure. Keep tightly closed when in operation. Ouvrir le circuit avant d enlever le couvercle. Garder le couvercle bien ferme tant que les circuits sont sous tension. 52 NW 42nd St Oklahoma City, OK kimray.com

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3 TABLE OF CONTENTS INTRODUCTION...6 INSTALLATION...7 CONNECTING THE BK3000 TO A FREQUENCY OUTPUT DEVICE...7 POWER CONNECTIONS...10 OPERATING THE MONITOR...12 PROGRAMMING MODE...12 PROGRAMMING USING FREQUENCY OUTPUT TURBINE FLOW METERS...13 ESSENTIALS...13 PROGRAMMING PARAMETERS...14 CONVENTIONS...14 GAS COMPENSATION...20 SETPOINTS...27 APPENDIX...31 TROUBLESHOOTING GUIDE...31 DEFAULT K-FACTOR VALUES...31 BATTERY REPLACEMENT...32 SPECIFICATIONS...34 LIQUID MENU MAPS...37 GAS MENU MAPS...40 K-FACTORS EXPLAINED...43 SYMBOL EXPLANATIONS...46 EXPLOSION-PROOF ENCLOSURE...47 BK3000 MODBUS INTERFACE...50 MODBUS REGISTER / WORD ORDERING...50 REGISTER MAPPINGS...51 OPCODE 01 READ COIL STATUS...52 OPCODE 03 READ HOLDING REGISTERS...52 OPCODE 05 FORCE SINGLE COIL...53 C SOURCE CODE...54 WASTE ELECTRICAL AND ELECTRONIC EQUIPMENT (WEEE) DIRECTIVE...55 CONTACTS AND PROCEDURES...56 LIMITED WARRANTY AND DISCLAIMER...57 NOTES...58 NOTE: Kimray reserves the right to make any changes or improvements to the product described in this manual at any time without notice. 3

4 FIGURES FIGURE 1 - BK3000 FLOW MONITOR (NEMA 4)...6 FIGURE 2 - BK3000 FLOW MONITOR (EX-PROOF)...6 FIGURE 3 - INPUT JUMPER SETTINGS NEMA FIGURE 4 - INPUT JUMPER SETTINGS EX-PROOF...7 FIGURE 5 - TYPICAL MAGNETIC PICKUP CONNECTION (NEMA 4)...8 FIGURE 6 - TYPICAL MAGNETIC PICKUP CONNECTION (EX-PROOF)...8 FIGURE 7 - TYPICAL AMPLIFIED PICKUP CONNECTION (NEMA 4)...9 FIGURE 8 - TYPICAL AMPLIFIED PICKUP CONNECTION (EX-PROOF)...9 FIGURE 9 - LOOP POWER CONNECTIONS (NEMA 4)...10 FIGURE 10 - LOOP POWER CONNECTIONS (EX-PROOF)...10 FIGURE 11 - REQUIRED GROUNDING FOR EXPLOSION PROOF ENCLOSURE...10 FIGURE 12 - SOLAR POWERED BK FIGURE 13 - DISPLAY ANNUNCIATORS...12 FIGURE 14 - KEYPAD DETAIL...12 FIGURE 15 - PROGRAMMING MODE DISPLAY...14 FIGURE 16 - INSTANTANEOUS FLOW RATE AND CURRENT TOTAL...15 FIGURE 17 - GRAND TOTAL...16 FIGURE 18 - TEST MODE SCREEN...16 FIGURE 19 - OPEN DRAIN CONNECTIONS (NEMA 4)...22 FIGURE 20 - OPEN DRAIN CONNECTIONS (EX-PROOF)...22 FIGURE 21 - OPTO-ISOLATED OPEN COLLECTOR CONNECTIONS (NEMA 4)...22 FIGURE 22 - OPTO-ISOLATED OPEN COLLECTOR CONNECTIONS (EX-PROOF)..22 FIGURE MA CALIBRATION SETUP...23 FIGURE 24 - SETPOINT OUTPUT (NEMA 4)...27 FIGURE 25 - SETPOINT OUTPUT (EX-PROOF)...27 FIGURE 26 - SETPOINT ACTIONS...28 FIGURE 27 - SETPOINT EXAMPLE...29 FIGURE 28 - CIRCUIT BOARD REMOVAL...33 FIGURE 29 - BATTERY REPLACEMENT PARTS IDENTIFICATION

5 TABLES TABLE 1 - DISPLAY MODE SELECTION INFORMATION...14 TABLE 2- SAMPLE LINEARIZATION DATA...25 TABLE A1 - LIQUID K-FACTORS...31 TABLE A2 - GAS K-FACTORS...31 TABLE A3 - APPROVALS...47 TABLE MB1 - MODBUS COMMANDS...50 TABLE MB2 - AVAILABLE DATA FORMATS...50 TABLE MB3 - MODBUS REGISTER MAP FOR LITTLE-ENDIAN WORD ORDER MASTER DEVICES...51 TABLE MB4 - MODBUS REGISTER MAP FOR BIG-ENDIAN WORD ORDER MASTER DEVICES...51 TABLE MB5 - MODBUS COIL MAP...52 TABLE MB6 - READ COIL STATUS...52 TABLE MB7 - FORCE SINGLE COIL

6 INTRODUCTION The BK3000 flow monitor incorporates state-of-the-art, digital signal processing technology, designed to provide the user with exceptional flexibility at a very affordable price. Though designed for use with Kimray flow sensors, this monitor can be used with almost any flow sensor producing a low amplitude AC output or contact closure signal. This monitor is capable of accepting low-level frequency input signals typically found in turbine flow sensors. The output signal for these type of sensors is a frequency proportional to the rate of flow. The BK3000 monitor uses the frequency information to calculate flow rate and total flow. Through the use of the programming buttons the user can select rate units, total units and unit time intervals among other functions. All BK3000 flow monitors come pre-configured from the factory, if ordered with a Kimray flow sensor. If required, however, it can easily be re-configured in the field. Finally, the user can choose between simultaneously showing rate and total, or alternating between rate and grand total. 1 2 S3 S2 J1 FIGURE 1 - BK3000 FLOW MONITOR (NEMA 4) FIGURE 2 - BK3000 FLOW MONITOR (EX-PROOF) The monitor is available in two different levels of functionality and two packaging options. The Base model provides all the functions necessary for the most common flow metering applications. The Advanced version adds communications capabilities over an RS485 bus using Modbus RTU and control outputs. Completing the line is a solar powered model (NEMA 4X Only). Packaging options include a polycarbonate, NEMA 4X version and an aluminum explosion proof enclosure. 6

7 INSTALLATION CONNECTING THE BK3000 TO A FREQUENCY OUTPUT DEVICE Most turbine flow sensors produce a frequency output that is directly proportional to the volumetric flow through the sensor. There are, however, different output waveforms that can be presented to the display device depending on the transducer that converts the mechanical motion of the turbine into an electrical signal. The BK3000 monitor has two jumpers that are used to set the type of signal and the minimum amplitude of the signal that it will accept. The first thing that must be established is the type of output provided by the flow sensor. The outputs almost always fall into one of two types. Type 1 - This is the unaltered frequency signal that comes from an un-amplified magnetic pickup. This signal is normally a sine wave in appearance and the amplitude of the waveform varies with the flow. Small turbines have comparatively small rotating masses so they produce a smaller amplitude waveform and higher frequencies than larger turbine sensors. Type 2 - The frequency signal from the transducer is amplified, wave shaped or both to produce a waveform of a specified type and amplitude. Most amplified transducers output a square wave shape at one of many standard amplitudes. For example a popular amplified output is a 10 VDC square wave. If the flow sensors output signal is type 1 the minimum amplitude of the frequency output must also be determined. The BK3000 has a high and low sensitivity setting. High sensitivity (30 mv) would be used with low amplitude (usually small) turbine flow sensors. The Low sensitivity setting (60 mv) would typically be used for larger turbines and amplified transducers (See Figures 3 & 4). NOTE: The High setting should only be used where the minimum signal amplitude is below 60 mv. Setting the sensitivity lower than necessary opens the instrument up to a greater possibility of noise interference. SSFM-013 BK3000 Manual 7 7

8 TB1 JP1 Pulse Mag JP2 OC Iso JP3 High Low Input Total Pulse Signal Input Waveform Selection (Magnetic Pickup Selection Shown) Input Signal Level Selection (Low Sensitivity (60 mv) Selection Shown) P1 P1 TB1 Gnd Input Signal Level Selection (Low Sensitivity (60 mv) Selection Shown) High Low Signal Input Waveform Selection (Magnetic Pickup Selection Shown) JP2 JP1 Pulse Input Mag Freq. In TB2 FIGURE 3 - INPUT JUMPER SETTINGS NEMA 4 FIGURE 4 - INPUT JUMPER SETTINGS EX-PROOF Once the type of waveform and input signal level (amplitude) have been determined the jumpers on the BK3000 circuit board can be set. For typical variable reluctance magnetic pickups the waveform selection jumper should be set for Mag. The setting for the input level must be determined from looking at the magnetic pickup specifications. If the minimum amplitude at the minimum rated flow is greater than 60 mv use the Low Signal jumper position (See Figures 5 & 6). If the minimum signal level is below 60 mv use the High Signal jumper position. Again all BK3000 flow monitors come pre-configured from the factory, if ordered with a Kimray flow sensor. 8

9 TR_B TR_A RS485 Gnd Setpoint 1 Setpoint 2 Gnd Freq. In 4-20mA Iso Total Pluse Total Reset OC Total Pluse Signal Gnd TB1 P1 JP1 JP2 JP3 P2 P1 TB1 Gnd Setpoint 2 Setpoint 1 RS485 Gnd TR_A TR_B JP2 High Low Signal Input JP1 Pulse Mag TB2 Freq. In 4-20mA Iso Total Pluse Total Reset OC Total Pluse Signal Gnd ISO OC Total Pulse JP3 Pulse Mag OC Iso High Low Input Total Pulse Signal JP1 Pulse Mag Input P1 Input JP1 Pulse Mag 3.6Vdc Battery FIGURE 5 - TYPICAL MAGNETIC PICKUP CONNECTION (NEMA 4) FIGURE 6 - TYPICAL MAGNETIC PICKUP CONNECTION (EX-PROOF) For amplified input signals the Input jumper should be set to Pulse and the Signal jumper set to Low (See Figures 7 & 8). NOTE: Amplified magnetic pickups will require an external power source. The BK3000 does not supply power to the amplified pickup. 9

10 TR_B TR_A RS485 Gnd Setpoint 1 Setpoint 2 Gnd Freq. In 4-20mA Iso Total Pluse Total Reset OC Total Pluse Signal Gnd TB1 P1 JP1 Pulse Mag JP2 OC Iso JP3 High Low P2 P1 P1 TB1 Gnd Setpoint 2 Setpoint 1 RS485 Gnd TR_A TR_B JP2 High Low Signal Input JP1 Pulse Mag TB2 Freq. In 4-20mA Iso Total Pluse Total Reset OC Total Pluse Signal Gnd ISO OC Total Pulse JP3 Input JP1 Pulse Mag Input Total Pulse Signal JP1 Pulse Mag Input POWER SUPPLY 3.6Vdc Battery POWER SUPPLY FIGURE 7 - TYPICAL AMPLIFIED PICKUP CONNECTION (NEMA 4) FIGURE 8 - TYPICAL AMPLIFIED PICKUP CONNECTION (EX-PROOF) POWER CONNECTIONS STANDARD The BK3000 has two power supply options. The standard power supply is an internal lithium 3.6 VDC D cell that will power the monitor for about 6 years with no outputs being used. The monitor can also derive power from a 4-20 ma current loop (See Figures 9 & 10). If the current loop is used, a sensing circuit within the monitor detects the presence of the current loop and disconnects the battery from the circuit. P1 P1 TB1 Gnd Setpoint 2 Setpoint 1 RS485 Gnd TR_A TR_B JP2 High Low Signal Input JP1 Pulse Mag TB2 Freq. In 4-20mA Iso Total Pluse Total Reset 10 to 28 VDC 4-20 ma Current Loop (10 to 28 VDC) Load The explosion proof enclosure is provided with a grounding screw on the inside of the enclosure. The conductor used for grounding must be of a wire gage equal to or greater than the signal wires being used. OC Total Pluse P2 3.6Vdc Battery Signal Gnd ISO OC Total Pulse JP3 To Earth Ground FIGURE 10 - LOOP POWER CONNECTIONS (EX-PROOF) FIGURE 11 - REQUIRED GROUNDING FOR EXPLOSION PROOF ENCLOSURE 10 10

11 TR_B TR_A P1 RS485 Gnd Setpoint 1 Setpoint 2 10 to 28 VDC 4-20 ma Current Loop (10 to 28 VDC) Load Gnd Freq. In 4-20mA Iso Total Pluse Total Reset OC Total Pluse JP1 Pulse Mag JP2 OC Iso JP3 High Low Input Total Pulse Signal Signal Gnd TB1 FIGURE 9 - LOOP POWER CONNECTIONS (NEMA 4) Caution: Grounding for the explosion proof enclosure is necessary. The explosion proof enclosure is provided with a grounding screw on the inside of the enclosure. The conductor used for grounding must be of a wire gage equal to or greater than the signal wires being used. See Figure 11 SOLAR An optional solar powered variant is also available. The solar cell mounted on the top of the monitor charges an internal 3.6 VDC nickel-cadmium battery that powers the monitor. A fully charged Ni-Cad will run the monitor for approximately 30 days. The solar powered BK3000 has a single totalizing pulse output and cannot be powered by a 4-20 ma loop. SSFM-013 BK3000 Manual 11 11

12 Solar Cell 1 2 FIGURE 12 - SOLAR POWERED BK3000 OPERATING THE MONITOR The monitor has three modes of operation referred to as the RUN, PROGRAMMING, and EXTENDED PROGRAMMING modes. 12

13 Communications Indicator Alarm Activation Rate 1 2 Battery Indicator Rate Units Total Totalizer Multiplier Totalizer Units FIGURE 13 - DISPLAY ANNUNCIATORS To access the PROGRAM mode, momentarily press and then release the MENU button until the first programming screen is displayed. The EXTENDED PROGRAMMING mode is entered by pressing and holding the MENU button until the first programming option appears. After programming the display with the necessary information, a lock out feature can be turned on to prevent unauthorized access or changing of the meter s setup parameters. PROGRAMMING MODE K COM 1 2 Menu S1 S4 K Enter COM Up S3 S2 FIGURE 14 - KEYPAD DETAIL BUTTONS MENU Switches between normal running and programming modes. UP Arrow ( ) In programming mode scrolls forward through the parameter choices and incre- SSFM-013 BK3000 Manual 13 13

14 ments numeric variables. RIGHT Arrow ( ) In programming mode scrolls backward through the parameter choices and moves the active digit to the right. ENTER Used to save programming information, advance to the next programming parameter, and in the reset process. TOTAL FLOW RESET - This touch sensor button allows the total to be reset without opening up the case. This button pertains to the Explosion Proof version only SPECIAL FUNCTIONS MENU ENTER - Simultaneously press and hold to reset the current totalizer. MENU - Press and hold menu key for 3 seconds to enter extended programming mode. UP Arrow ( ) Right Arrow ( ) - Simultaneously press and hold to show the firmware version number, then the grand total. UP Arrow ( ) - In run mode increases display contrast. RIGHT Arrow ( ) - In run mode decreases display contrast. MODES RUN Normal operating mode. PROGRAM Used to program variables into the display. EXTENDED PROGRAM Used to program advanced variables into the display. TEST Used as a diagnostic tool to show input frequency and totalizer counts. If your monitor was ordered with a Kimray flow sensor, the two components ship from the factory configured as a set. If the monitor is a replacement, the turbine s K-factor has changed, or the monitor is being used with some other pulse generating device; programming will be necessary. PROGRAMMING USING FREQUENCY OUTPUT TURBINE FLOW METERS Each Kimray turbine flow meter is shipped with either a K-factor value or frequency data. If frequency data is provided, the data must be converted to a K-factor before programming the monitor. K-factor information, when supplied, can usually be found on the neck of the flow meter or stamped on the flow meter body. The K-factor represents the number of pulses per unit of volume (See K-Factors Explained in the Appendix). The K-factor will be needed to program the monitor. ESSENTIALS The BK3000 monitor was engineered to provide several levels of programming tailored to the needs of the user. The first or standard level provides access to the most commonly used setup parameters bypassing the more advanced settings. The first level programming is entered by pressing and holding the MENU button for about 1 second. The second level or extended settings are accessed by pressing and holding the MENU button until the extended programming menu starts. With the Standard and Solar liquid monitors there is a third level. For the most basic unit setup choices the BK3000 monitor has a Simple and Advanced setup option accessed through the Rate SU (Rate Setup) parameter. If Simple is chosen the rate and total choices are reduced to the five most common combinations avoiding the need to make unit and interval choices. 14

15 Liquid Meters Standard Solar Advanced I/O Basic Functions Press the MENU for about 1 second and then release. Extended Functions Press and Hold MENU button until the extended programming menu starts Simple Setup Select Rate SU in the Extended Functions and choose Simple. Advanced Setup Select Rate SU in the Extended Functions and choose Advanced. Not Applicable TABLE 1 - DISPLAY MODE SELECTION INFORMATION ENTER PROGRAM MODE The programming modes are accessed by pressing the MENU button once for basic functions. Extended functions are accessed by pressing and holding the MENU button until the first programming parameter appears. Numeric Values 1 2 Battery Indicator Units Indicator Function Totalizer Multiplier Totalizer Units FIGURE 15 - PROGRAMMING MODE DISPLAY PROGRAMMING PARAMETERS CONVENTIONS The individual programming parameters are arranged as follows. 15

16 Top Line - Indicates what the parameter is and if it is a Selection or an Entry. Bottom Line - Indicates what menu level the parameter resides in. SELECT FLUID TYPE (Fluid) Basic Function At the Fluid Type prompt use the or buttons to select either Liquid or Gas. NOTE: The fluid selection choice will affect what menu choices are available to the user. Consult the full Menu Maps in the appendix for further details. NOTE: The following programming assumes the meter is set for Liquid. Parameters for gaseous fluids can be found later in the manual. SELECT METER SIZE (Meter) Basic Function At the Meter prompt press the ENTER key to show the current meter size. Use the or buttons to select the correct meter size and press ENTER again to advance to the next parameter. NOTE: The meter size selection refers to the bore of the meter and not the connections size. For a listing of the Kimray turbine bore sizes see the Default K-Factor table in the appendix. SELECT DISPLAY FUNCTION (Display) Extended Function The BK3000 monitor has three display selections. (1) Flow (Flow) The Flow (Flow) setting is used for normal operation of the monitor. In this mode the display shows both the instantaneous flow rate and current total simultaneously. See Figure 16. Instantaneous Flow Rate 1 2 Flow Rate Units Totalizer Multiplier Current Total Current Total Units FIGURE 16 - INSTANTANEOUS FLOW RATE AND CURRENT TOTAL (2) GRAND TOTAL (G-Total) 16

17 The Flow Grand Total (Flow G-T) choice forces the meter to alternate between the instantaneous flow and the grand total with roll-over counts. See Figure 17. The grand total is the accumulation of all the fluid that has gone through the meter sense the last time the grand total was cleared. This totalizer is in addition to the current total totalizer on the display and is always enabled. In addition the grand total screen also displays the number of times the grand total has reached its maximum count (9,999,999) and rolled over to zero. Roll-Overs 1 2 Roll-Over Indicator Total Totalizer Mode FIGURE 17 - GRAND TOTAL (3) Test (Test) The Test (Test) setting places the monitor into a special diagnostic mode that shows the current input frequency and the accumulated input counts. Figure 18 shows the layout for test mode values. The diagnostic mode makes it possible for the user to see precisely the frequency input the monitor is seeing and is very useful in troubleshooting and noise detection. Input Frequency 1 2 FIGURE 18 - TEST MODE SCREEN Totalizer Counts If the current setting requires a change, press the arrow key to advance to the alternate choice. Once the correct choice is displayed, press ENTER key once to save the new selection and advance to the next parameter. SELECT METER S K-FACTOR UNIT (KFacUnt) Basic Function 17

18 At the K-Factor Unit prompt, press the ENTER key once. The display now shows the current K-factor unit. If the current selection is correct, press the ENTER key to advance to the next parameter. For meters calibrated in gallons, use Pul/Gal; for meters calibrated in cubic meters, use Pul/m3; etc. ENTER FLOW SENSORS K-FACTOR (KFactor) Basic Function NOTE: The K-factor supplied with your meter or calculated from calibration data will be needed to complete this step. At the K-factor (KFactor) prompt, press the ENTER key once. The most significant digit in the K-factor will begin to flash. Using the arrow key, increment the display digit until it matches the meter s K-factor digit. If the current selection is correct, press the arrow key to advance to the next digit. Repeat this process until all K-factor digits have been entered. Press ENTER once to save the K-factor. NOTE: The number of digits available before and after the decimal point is determined by the bore size of the flow sensor being used. The largest K-factors will be associated with the smallest bore sizes. The maximum allowable K-factor is The minimum must be at least If an out of range number is entered the display will flash Limit (Limit) and refuse to allow the entry. SELECT RATE UNIT SETUP (Rate SU) Extended Function The Rate Unit Setup (Rate SU) is only available on the Standard and Solar liquid monitors. For the most basic unit setup choices the BK3000 monitor has a Simple and Advanced setup option accessed through the Rate Setup parameter. If Simple is chosen the rate and total choices are reduced to the five most common combinations avoiding the need to make unit and interval choices. When Advanced is selected the monitor allows access to all rate, total, and interval parameters. SELECT FLOW RATE UNITS (Flo Unit) Basic Function (Simple Setting) The monitor allows the choice of many common rate units. Consult the Menu Maps or the Specifications in the appendix for all the unit choices. At the Flow Unit (Flo Unit)prompt, press the ENTER key once. The monitor now shows the current rate and totalizer units choice flashing on and off. If the current selection is correct, press the ENTER key to advance to the next parameter. To change to an alternate unit, use the or buttons to scroll to the desired rate unit and press ENTER to save the choice. SELECT RATE (TIME) INTERVAL (RateInt) Basic Function (Advanced Setting) The term rate implies that something is occurring over a period of time. Most people are familiar with the speed of a car reported in miles per hour (MPH). The same concept holds true for a flow meters based on sensing velocity. The time choices are Sec (seconds), Min (minutes), Hour (hours), and Day (days). At the Rate Interval prompt, press the ENTER key once. The monitor now shows the current time interval choice flashing on and off. If the current selection is correct, press the ENTER key once to advance to the next parameter. To change to an alternate time interval, use the use the or buttons to scroll to the desired time interval and press ENTER to save the choice. 18

19 SELECT FLOW RATE UNITS (RateUnt) Basic Function (Advanced Setting) The monitor allows the choice of many common rate units. Consult the Menu Maps or the Specifications in the appendix for all the unit choices At the Rate Unit (RateUnt) prompt, press the ENTER key once. The monitor now shows the current rate unit choice flashing on and off. If the current selection is correct, press the ENTER key to advance to the next parameter. To change to an alternate unit, use the or buttons to scroll to the desired rate unit and press ENTER to save the choice. SELECT TOTAL UNITS OF MEASURE (TotlUnt) Basic Function (Advanced Setting) If a flow total is desirable, the units for the total must first be chosen. The monitor allows the choice of many common totalization units. Consult the Menu Maps or the Specifications in the appendix for all the unit choices. At the Total Unit (TotlUnt) prompt, press the ENTER key once. The monitor shows the current total units. If the current selection is correct, press the ENTER key once to advance to the next parameter. To change to an alternate unit, use the or buttons to scroll to the desired totalization unit and press ENTER to save the choice. SELECT TOTAL MULTIPLIER (TotlMul) Basic Function (Advanced Setting) The monitor has a very versatile display that has the ability to accumulate the flow total in multiples of ten. For example, if the most desirable totalization unit is 1,000 gallons, the monitor can easily be set up for this requirement. Once the unit is back in run mode, every time the total display increments by one digit the actual total would be an additional 1,000 gallons. At 1,000 gallons the total display would read 1, at 3,000 gallons the total display would read 3, etc. This feature eliminates having to look at a total, count the digits, and mentally insert commas for each 1,000 multiple. At the Total Multiplier (TotlMul) prompt, press the ENTER key once. The monitor now shows the current total multiplier. If the selection is correct, press the ENTER key to advance to the next parameter. To change to an alternate multiplier, use the or buttons to scroll to the desired multiplier unit and press ENTER to save the choice. The multiplier choices: 0.01 ( 100), 0.1 ( 10), 1, x10, x100, x1000 units ENTER SPECIFIC GRAVITY VALUE (Spec Gr) Basic Function (activated when mass units are selected) The BK3000 has two mass flow unit and two mass total unit choices (pounds and kilograms). When either pounds or kilograms are chosen in either the Rate Units (RateUnt) or Total Units (TotlUnt) parameters the Specific Gravity (Spec Gr) entry parameter is activated. Mass readings in the BK3000 are not temperature or pressure compensated so it is best to enter the specific gravity of the fluid as close to the system running temperature as possible. As liquids are essentially incompressible pressure compensation is not necessary for liquids. ENTER A SCALE FACTOR (Scale F) Extended Function 19

20 The scale factor is used to force a global span change. For example, under operating conditions the display is reading a consistent 3% below the expected values at all flow rates. Rather than changing the K-factor and linearization parameters individually, the scale factor can be used to compensate for the 3% offset. The scale factor would be set to 1.03 to correct the readings. The range of scale factors is from 0.10 to The default scale factor is At the Scale Factor (Scale F) prompt, press the ENTER key once. The first digit of the existing scale factor, if any, will begin to flash. If the current selection is correct, press the ENTER key to advance to the next parameter. If the current selection requires a change, use the arrow key, increment the display digit until it matches the first digit of the new scale factor. Next press the arrow key to advance to the next digit and using the arrow key, increment the second display digit until it matches the second digit of the new scale factor. Repeat this step for the third digit. Press ENTER once to save the new scale factor. NOTE: If an out of range number is entered the display will flash Limit (Limit) and refuse to allow the entry. PRESET TOTAL (SetTotl) Extended Function It is sometimes helpful to be able to set the totalizer to a predetermined number before starting a process. The BK3000 allows this through the use of the set total menu entry. The preset is capable of seven digits or up to 8,888,888. P 1 V 1 P = 2 V 2 T 1 T 2 At the Preset Total (SetTotl) prompt, press the ENTER key twice. The first digit of the current preset total will begin to flash. If the current selection is correct, press the ENTER key to advance to the next parameter. If the current selection requires a change, use the arrow key, increment the display digit until it matches the first digit of the desired preset. Next press the arrow key to advance to the next digit and using the arrow key, increment the second display digit until it matches the second digit of the preset. Repeat this step until the preset is complete. Press ENTER once to save the new preset. NOTE: If an out of range number is entered the display will flash Limit (Limit) and refuse to allow the entry. LOW FLOW CUTOFF (Cutoff) Extended Function A Low Flow Cut-off entry is provided to allow low flow rates (that can be present when pumps are off and valves are closed) to be displayed as zero flow. A typical value would be about 5% of the flow sensors maximum flow. This setting is a good compromise between suppression of noise and utilizing the full span of the flow sensor. 20 SSFM-013 BK3000 Manual 20

21 The low flow cutoff is entered as an actual flow value. For example if the maximum flow rate for the flow sensor was 100 GPM the low flow cutoff values should be set for 5% of 100 GPM. The entry would then be 5.0. At the Low Flow Cut-off (Cutoff) prompt, press the ENTER key once. The first digit of the current low flow cut-off will begin to flash. If the current selection is correct, press the ENTER key to advance to the next parameter. If the current selection requires a change, use the arrow key, increment the display digit until it matches the first digit of the desired low flow cut-off value. Next press the arrow key to advance to the next digit and using the arrow key, increment the second display digit until it matches the second digit of the preset. Repeat this step until the low flow cut-off is entered. Press ENTER once to save the new low flow cut-off. NOTE: If an out of range number is entered the display will flash Limit (Limit) and refuse to allow the entry. GAS COMPENSATION (Gas Turbines Only) Fluid measured by the gas turbine meter is compressible, and is also affected by temperature changes and pressure changes as illustrated by the ideal gas law equation (Equation 1): Absolute Pressure and Temperature Equation 1 The ideal gas law equation shows that the volume of gas is determined by pressure and temperature applied to the gas under running conditions. In this equation, the pressure, P, is absolute pressure the observed gauge pressure plus the atmospheric pressure. The commonly used domestic unit of measure for absolute pressure is pounds per square inch absolute (psia). Atmospheric pressure is considered to be psi. Therefore, Absolute pressure (psia) is the sum of the gage pressure plus The absolute temperature in the equation above is expressed in degrees Rankine, which is calculated by adding to the temperature in F. Because pressure and temperature have a large impact on the mass of gas moving through the flow meter both values must be entered into the BK3000 for accurate gas readings to occur. NOTE: The BK3000 calculates the correct pressure and temperature values without having to convert to absolute pressure or degrees Rankine. The compensation values should be entered in psig and F. SSFM-013 BK3000 Manual 21 21

22 Operating Pressure (Op Pres) Basic Function (Gas Only) At the Operating Pressure (Op Pres) prompt, press the ENTER key. The first digit of the current pressure setting will begin to flash. If the current selection requires a change, use the arrow key, increment the display digit until it matches the first digit of the desired pressure value. Next press the arrow key to advance to the next digit and using the arrow key, increment the second display digit until it matches the second digit of the operating pressure. When the correct pressure setting has been entered, press ENTER once to save the new pressure value. Operating Temperature (Op Temp) Basic Function (Gas Only) At the Operating Temperature (Op Temp) prompt, press the ENTER key. The first digit of the current temperature setting will begin to flash. If the current selection requires a change, use the arrow key, increment the display digit until it matches the first digit of the desired temperature value. Next press the arrow key to advance to the next digit and using the arrow key, increment the second display digit until it matches the second digit of the operating temperature. When the correct pressure setting has been entered, press ENTER once to save the new temperature value. DAMPING FACTOR (Damping) Extended Function The damping factor is increased to enhance the stability of the flow readings. Damping values are decreased to allow the monitor to react faster to changing values of flow. This parameter can take on any value between 0 and 99 % with 0 being the default. At the Damping prompt, press the ENTER key once. The current damping setting will begin to flash. If the current selection is correct, press the ENTER key to advance to the next parameter. If the current selection requires a change, use the arrow key, increment the display digit until it matches the first digit of the desired damping value. Next press the arrow key to advance to the next digit and using the arrow key, increment the second display digit until it matches the second digit of the damping value. Press ENTER once to save the new damping value. TOTALIZER PULSE OUTPUT (PulsOut) Basic Function The Pulse Output (PulsOut) parameter can be either Enabled or Disabled. When enabled, this output generates a fixed width 30 ms duration, pulse every time the least significant digit of the totalizer increments. The amplitude of the pulse is dependent on the voltage level of the supply connected to the pulse output and is limited to a maximum 28 VDC

23 The BK3000 provides two types of totalizer pulses. The basic open drain FET output, Figures 19 & 20, provides a ground referenced output pulse that swings between about 0.7 VDC and V CC. P1 TR_B TR_A Input JP1 Pulse Mag RS485 Gnd TB2 2.2 to 10K Pull-up Resistor Open Drain FET Total Pulse Output V CC 100 ma Maximum Setpoint 1 Setpoint 2 FIGURE 19 - OPEN DRAIN CONNECTIONS (NEMA 4) Gnd Freq. JP1 In 4-20mA JP2 Iso Total Pluse JP3 Total Reset Total Pluse Signal Gnd TB1 Pulse Mag OC Iso High Low Input Total Pulse Signal Internal 2.2 to 10K Pull-up Resistor Open Drain FET Total Pulse Output V CC 100 ma Maximum Freq. In 4-20mA Iso Total Pluse Total Pulse Total Reset OC Total Pluse Signal Gnd FIGURE 20 - OPEN DRAIN CONNECTIONS (EX-PROOF) ISO JP3 OC Internal The isolated pulse output (ISO), Figures 21 & 22, are again an open collector output with the emitter of the transistor connected to the negative output terminal and is not referenced to ground. This output is optically isolated from the input signal for systems that require a totally isolated output pulse. 2.2 to 10K Pull-up Resistor Isolated Output Total Pulse V V CC 100 ma Maximum TR_B TR_A RS485 Gnd Setpoint 1 Setpoint 2 Gnd Freq. In 4-20mA Iso Total Pluse Total Reset OC Total Pluse Signal Gnd JP1 Pulse JP2 OC JP3 High FIGURE 21 - OPTO-ISOLATED OPEN COLLECTOR CONNECTIONS (NEMA 4) TB1 Mag Iso Low P1 Input Total Pulse Signal Internal 2.2 to 10K Pull-up Resistor Isolated Output Total Pulse V V CC 100 ma Maximum Freq. In 4-20mA Iso Total Pluse Total Pulse Input JP1 Pulse Mag Total Reset OC Total Pluse Signal Gnd ISO JP3 OC FIGURE 22 - OPTO-ISOLATED OPEN COLLECTOR CONNECTIONS (EX-PROOF) TB2 Internal Both outputs have a maximum current capacity of 100 ma and require a pull-up resistor. The value of the pull-up resistor is dependent on the supply voltage and the maximum current required by the load device. FLOW 20 ma (Fl=20mA) Basic Function When the display is operated using loop power, the flow rate that corresponds to 20 ma must be set

24 AutoHOLD FAST MIN MX LOGGING YES HOLD MIN MAX REL SETUP A FAST MAX MIN AVG LOG HOLD 0 MEM 0 acdc OFF 10A MAX FUSED CANCEL SAVE NO Hz % ms RANGE ns 400mA FUSED COM HM MS CAT III 1000V acdc VIEW MEM CLEAR MEM acdc TEMPERATURE W V This setting normally represents the maximum rate of the flow sensor connected to the display but other entries are possible. % AUTO MANUAL At the Flow at 20 ma (Fl=20mA) prompt, press the ENTER key once. The current setting will begin to flash. If the current setting is correct, press the ENTER key to advance to the next parameter. V db V mv db mv acdc μa ma W C F ma A μa μa A ma If the current setting requires a change, use the arrow key, increment the display digit until it matches the first digit of the desired maximum flow value. Next press the arrow key to advance to the next digit and using the arrow key, increment the second display digit until it matches the second digit of the desired value. Repeat this step until the maximum flow at 20 ma is entered. Press ENTER once to save the new flow value ma CALIBRATION (4-20Cal) Extended Function 4-20 ma Current Loop (11 to 30 VDC) POWER SUPPLY TR_B TR_A RS485 Gnd Setpoint 1 Setpoint 2 Gnd Freq. In 4-20mA Iso Total Pluse Total Reset OC Total Pluse Signal Gnd TB1 Pulse Mag OC Iso High Low P1 JP1 JP2 JP3 Input Total Pulse Signal This menu item allows the fine adjustment of the Digital to Analog Converter (DAC) that controls FIGURE MA CALIBRATION SETUP 4-20 ma output. The 4-20 ma output is calibrated at the factory and under most circumstances does not need to be adjusted. If the output needs to be adjusted for whatever reason the 4-20 ma calibration procedure can be used. The DAC used in the BK3000 is an 12 bit device so the valid entries range from 0 to ma ADJUSTMENT (4mA Out) To set the 4 ma value, connect an ammeter in series with the loop power supply as shown in Figure 14. At the 4-20Cal prompt, press ENTER once. The display will now show a steady NO indication. Press the arrow key to change to a YES display and then press enter. The 4 ma DAC setting is typically between 35 and 50. Using the and arrow buttons while monitoring the ammeter, adjust the 4 ma value to obtain a 4 ma reading on the ammeter. The arrow key increases the DAC value and the arrow key decreases the DAC value. When a steady 4 ma reading is obtained on the ammeter, press the ENTER key to lock in this value and move to the 20 ma adjustment. 20 ma ADJUSTMENT (20mAOut) The 20 ma adjustment is performed using the same procedure as the 4 ma adjustment. While monitoring the ammeter, adjust the 20 ma DAC value to obtain a 20 ma reading. The arrow key increases the DAC value and the arrow key decreases the DAC value. When a steady 20 ma reading is obtained on the ammeter, press the ENTER key to lock in this value and move to the next parameter ma TEST (4-20Tst) The BK3000 monitor contains a diagnostic routine that allows the simulation of ma output values between 4 and 20 to check output tracking. At the 4-20 TEST prompt the 24 24

25 current is shown as a flashing number. Use the arrow key to increase the simulated ma output in increments of 1 ma. The arrow key will decrease the ma output. The ammeter should track the simulated ma output. If a 4-20 ma test is not necessary, press the ENTER key once to move to the next parameter. NOTE: Pressing the ENTER key when the monitor is in test mode will exit the test mode and move on to the next programming parameter. LINEARIZATION (Linear) Extended Function Linear Coefficient = Actual K-Factor Nominal K-Factor Enhanced accuracy can be obtained by linearization of the display. The linearization function will accept a maximum of ten points. Linearization requires additional calibration data from the meter to be used with the monitor. Typically, calibration information can be obtained in three, five, and ten points from the flow meter s manufacturer. If linearization is not needed, press the arrow key to advance to the next parameter. The maximum number of linearization points is 10. Number of Points At the Linear (Linear) prompt, press ENTER once. The Linear Points (Lin Pts) value will be displayed. If the number of points is set to 0, linearization is disabled. Press ENTER and the most significant digit of the number of points entry will begin to flash. The first number can either be a 1 or a 0 only. Use the arrow key to change the first digit. Press the arrow key once to move to the least significant digit. NOTE: if a number other than 0 or 1 is entered in this field the display will flash Limit (Limit) indicating that am over range value has been entered when Enter is pressed. Again, the arrow key increments the value. When the number of points has been input, press the ENTER key once to move to the first linear points frequency entry. Data Entry NOTE: If the number of linear points is set to 1 the BK3000 assumes the user is entering the maximum frequency and coefficient. Further the meter assumes that the implied first point is at a frequency of 0 (zero) and a coefficient of 0 (zero). Frequency - Press the ENTER key once and the first linear point s frequency input (Freq#1) will begin to flash. Enter the frequency for the first linear point using arrow key to increment the numerical values and the arrow key to change the position of the number being entered. When the frequency value input is complete, press ENTER once again to change to the coefficient value (Coef#1) for the first linear point

26 Coefficient The coefficient is the value applied to the nominal K-factor to correct it to the exact K- factor for that point. The coefficient is calculated by dividing the actual K-factor for that point by the Average (Nominal) K-factor for the flow meter. At the Coefficient (Coef#1) prompt, enter the coefficient that corresponds to the frequency value previously entered. Press ENTER once to move to the scaling point. Continue entering pairs of frequency and coefficient points until all data has been entered. Press the ENTER key to move to the next parameter. NOTE: The frequency values must be entered in ascending order. If a lower frequency value is entered after a higher value the BK3000 will flash Limit followed by the minimum frequency value acceptable to the display. Example: The following is actual data taken from a 1 inch turbine flow sensor calibrated with water. Unit Under Test (UUT) Calibration Data Table In GPM UUT Frequency UUT Actual K-Factor (Hz x 60) Nominal K Actual GPM Hz Counts/Gallon GPM Linear Coefficient Raw Error % Rate SSFM-013 BK3000 Manual 26

27 Nominal K (NK) TABLE 2- SAMPLE LINEARIZATION DATA In this example the linear coefficient has already been calculated by the calibration program so all that is required is to enter 5 into the number of linear points (Lin Pts) parameter and then enter, in order, the five frequency, linear coefficient data pairs. MODBUS (Modbus) Extended Function The Modbus Output parameter can be either Enabled or Disabled. When enabled, this output allows communications with the BK3000 using the Modbus RTU protocol. For additional information see Modbus in the Appendix of this manual. At the Modbus prompt (Modbus), press the ENTER key once. The current state of the Modbus output will be shown. If the current state is correct, press the ENTER key to advance to the next parameter. If the current state requires a change, use either the or arrow buttons to toggle between state. When the proper state has been selected press ENTER. BUS ADDRESS (BusAddr) - If the Modbus output has been enabled a valid Modbus address must also be chosen. Every device communicating over the RS485 communications bus using the Modbus protocol must have a unique bus address. Address values range from 0 to 127 with 0 being the default. At the Bus Address (BusAddr) prompt, press the ENTER key once. The current setting will begin to flash. If the current setting is correct, press the ENTER key to advance to the next parameter. If the current setting requires a change, use the arrow key, increment the display digit until it matches the first digit of the desired bus address. Next press the arrow key to advance to the next digit and using the arrow key, increment the second digit until it matches the second digit of the desired address. Repeat this step for the third digit of the address and then press EN- TER once to save the new address and advance to the next parameter. SETPOINTS Setpoints allow the meter to signal when a specific flow condition has been achieved. They are commonly used to indicate high or low flow conditions that need to be attended to. The BK3000 has two open collector outputs controlled by the setpoint function. The setpoint transistors have the same current limitations and setup requirements as the totalizing pulse output transistors described previously (See Figure 24 & 25). Both Setpoint 1 and Setpoint 2 are configured using the same procedures but the hysteresis and tripping SSFM-013 BK3000 Manual 27 27

28 conditions can be different for each setpoint output. NOTE: In most instances the current capacity of an open collector transistor is not sufficient to operate old style counters that relied on relay contact closures. When used with basic counting circuits a solid state relay will most likely be needed. SETPOINT 1 (SetPt 1) Extended Function The setpoint is the flow value at which the output transistor changes state. It is set using the same units as the rate units are entered. V CC 2.2 to 10K Pull-up Resistor 100 ma Maximum TR_B TR_A P1 P1 P1 TB1 Open Collector Control Output 1 and 2 RS485 Gnd Setpoint 1 Setpoint 2 Gnd Freq. In 4-20mA Iso Total Pluse Total Reset OC Total Pluse Pulse Mag OC Iso High Low JP1 JP2 JP3 Input Total Pulse Signal Internal Internal Gnd Setpoint 2 Setpoint 1 RS485 Gnd TR_A TR_B P2 3.6Vdc Battery 100 ma Maximum V CC Open Collector Control Output 1 and to 10K Pull-up Resistor Signal Gnd TB1 FIGURE 25 - SETPOINT OUTPUT (EX-PROOF) FIGURE 24 - SETPOINT OUTPUT (NEMA 4) At the Setpoint 1 (SetPt 1)prompt, press the ENTER key once. The most significant digit of the current setting will begin to flash. If the current setting is correct, press the ENTER key to advance to the next parameter. If the current setting requires a change, press the arrow key to advance to the first digit of the desired setpoint value. Once the correct place is reached use the arrow key to increment the digit until it matches the first number of the desired setpoint. Use the arrow key to advance to the next digit of the desired setpoint value then use the arrow key, increment the display digit until it matches the next digit of the desired setpoint. Repeat this step for the all the digits of the setpoint and then press ENTER once to save the new setpoint and advance to the next parameter. HYSTERESIS 1 (HystSP1) Extended Function Hysteresis is used to modify how the output transistor reacts around a setpoint by taking recent history into account. Hysteresis prevents an output from turning on and off rapidly when the programed flow rate is at or very near the setpoint. For example, a low flow alarm is set to activate when the flow falls below a pre programed point. When the flow is reduced to the setpoint, even minute changes of flow above the setpoint will turn 28 SSFM-013 BK3000 Manual 28

29 the output off disabling the alarm. Without hysteresis, if the flow rate fluctuates slightly above and below the setpoint the output will rapidly cycle between on and off states. Another example is a thermostat controlling a heater. The thermostat turns the heater on when the temperature drops below A degrees, but won t turn it off until the temperature rises above B degrees. The temperature between A and B is know as the hysteresis. Thus the on/off output of the thermostat to the heater when the temperature is between A and B depends on the history of the temperature. This prevents rapid switching on and off as the temperature drifts around the setpoint. Refer to the graphical representation of the hysteresis setting as shown in Figure 26. The hysteresis value is set using the same units as the rate units are entered. At the Hysteresis (HystSP1) prompt, press the ENTER key once. The most significant digit of the current setting will begin to flash. If the current setting is correct, press the ENTER key to advance to the next parameter. If the current setting requires a change, press the arrow key to advance to the first digit of the desired hysteresis value. Once the correct place is reached use the arrow key to increment the digit until it matches the first number of the desired hysteresis. Use the arrow key to advance to the next digit of the desired hysteresis value then use the arrow key, increment the display digit until it matches the next digit of the desired hysteresis. Repeat this step for the all the digits of the hysteresis and then press ENTER once to save the new hysteresis and advance to the next parameter. Minimum Flow Output ON OFF Setpoint ON Setpoint Maximum Flow Output OFF Hysteresis FIGURE 26 - SETPOINT ACTIONS NOTE: Neither the Setpoint nor the Hysteresis values are checked against the meter size to see if they are appropriate. Care should be used when entering these values, especially in critical applications, as it is possible to enter inappropriate values preventing the outputs from working as expected. TRIP SP 1 (TripSP1) Extended Function The Trip parameter can be set for either High (High) or Low (Lo). When set to high the open collector transistor stops conducting and sends the output high when the setpoint is reached. The output SSFM-013 BK3000 Manual 29 29

30 will not go low again until the flow rate falls below the setpoint minus the hysteresis value. Similarly when set to low the, open collector transistor starts conducting sending the output low when the setpoint is reached. The output will not go high again until the flow rate exceeds the setpoint plus the hysteresis value. For example if the setpoint is set to 10 GPM, the hysteresis is set to 2 GPM and the trip SP is set to high (See Figure 26). When the flow goes above 10 GPM the OC transistor will stop conducting and the output will go high. The output will stay high until the flow rate drops below 8 GPM which is the setpoint (10 GPM) minus the hysteresis (2 GPM). Minimum Flow OFF (8 GPM) Setpoint (10 GPM) Output ON Maximum Flow Output OFF Hysteresis (2 GPM) FIGURE 27 - SETPOINT EXAMPLE 30

31 At the Trip Setpoint 1 (TripSP1) prompt, press the ENTER key once. The tripping condition setting will be displayed. If the current setting is correct, press the ENTER key to advance to the next parameter. If the current setting requires a change, press the arrow key to advance to the alternate choice. Once the correct choice is displayed, press ENTER key once to save the new trip condition and advance to the next parameter. CLEAR GRAND TOTAL (Clr G-T) Basic Function At the Clear Grand Total (Clr G-T ) prompt, press the ENTER key once. The display will now say no on the screen. To clear the grand total press either the arrow or the arrow key to change from no to yes. Press the ENTER key to select yes and advance to the next parameter. PASSWORD (Passwd) Basic Function Password protection prevents unauthorized users from changing programming information. Initially, the password is set to all zeros. If the current setting requires a change, press ENTER once at the Password (Passwd ) prompt. The first digit of the password will begin to flash. Use the arrow key to increment the digit until it matches the first number of the desired password. Use the arrow key to advance to the next digit of the desired password value then use the arrow key to increment the display digit until it matches the next digit of the desired password. Repeat this step for the all the digits of the password and then press ENTER once to save the new password and advance to the next parameter. RESET PASSWORD (RstPswd) Basic Function Reset password parameter prevents unauthorized users from manually resetting the flow monitor s main totalizer. Initially, the password is set to all zeros. To change the reset password, press ENTER once at the reset password prompt. The first digit of the password will begin to flash. Use the arrow key to increment the digit until it matches the first number of the desired password. Use the arrow key to advance to the next digit of the desired password value then use the arrow key to increment the display digit until it matches the next digit of the desired password. Repeat this step for the all the digits of the password and then press ENTER once to save the new password and advance to the next parameter. NOTE: Entering a Passwd in the password screen and leaving the password blank in the RstPswd screen allows for total resets (not requiring a password), but restricts programming modification. TROUBLESHOOTING GUIDE APPENDIX 31